Tool and method for conductive trace generation in a 3D model for a hybrid electro-mechanical 3D printer

Abstract

Methods, systems, and apparatus, including medium-encoded computer program products, for combining electronic circuitry with mechanical structures using a design tool to build hybrid electro-mechanical three-dimensional circuits for 3D printed devices. In some implementations, the design tool facilitates creation and placement of components and traces, and print preparation for additive manufacturing systems.

What is claimed is: 
     
       1. A system comprising:
 a user interface device; and 
 one or more computers operable to interact with the user interface device and programmed with a design tool configured to combine electronic circuitry with mechanical structures for use with designing hybrid electro-mechanical three-dimensional circuits for 3D printed devices; 
 wherein the design tool is configured to facilitate creation and placement of components and traces, and print preparation for additive manufacturing systems, including auto-routing of a trace path to maximize portions of the trace that lie in the same 3D-printing slices. 
 
     
     
       2. The system of  claim 1 , wherein the design tool is configured to enable a user to create a trace in a three dimensional model by freehand drawing or by clicking on control maps. 
     
     
       3. The system of  claim 2 , wherein the design tool is configured to position and orientate electronic components in relation to the three dimensional model using ray casting. 
     
     
       4. The system of  claim 3 , wherein the design tool is configured to create the trace on a surface of the three dimensional model, or aligned to a given slice plane within the three dimensional model, using interpolation. 
     
     
       5. The system of  claim 4 , wherein the design tool is configured to orient traces or components to a user defined grid of planes, and wherein the electronic circuitry is formed using silver ink and where in the mechanical structures are formed using plastic. 
     
     
       6. A method comprising:
 providing, using a computing device, a design tool comprising a database of components for placement in a model; 
 receiving, using the computing device, user input comprising a selection of one or more of the components from the database and one or more corresponding locations for placement of the one or more components in the model; 
 placing one or more electrical traces in the model, including aligning the one or more electrical traces to a user defined slice plane within the model; and 
 storing a geometry of the model, wherein the stored geometry comprises structural components, electrically conductive components, and electrical traces. 
 
     
     
       7. The method of  claim 6 , wherein receiving the user input comprises a selection of two or more of the components from the database, and
 wherein placing one or more electrical traces comprises receiving, using the computing device, user input placing the one or more electrical traces to connect the two or more components. 
 
     
     
       8. The method of  claim 6 , wherein placing one or more electrical traces comprises:
 receiving two or more control points; and 
 mapping a trajectory for the one or more traces to the user adjustable slice plane within the model based on the two or more control points. 
 
     
     
       9. The method of  claim 8 , further comprising interpolating the trajectory based on the received two or more control points. 
     
     
       10. The method of  claim 6 , wherein placing one or more electrical traces comprises automatically placing, using the computing device, one or more electrical traces to connect two or more components. 
     
     
       11. The method of  claim 10 , wherein each electrical trace is automatically placed after a user selects two components from the selected two or more components. 
     
     
       12. The method of  claim 11 , further comprising, after automatically placing a first electrical trace, receiving a user input to re-shape the first electrical trace. 
     
     
       13. The method of  claim 6 , wherein the user defined slice plane is a first slice plane, the method further comprising receiving user input defining a second slice plane, and wherein placing one or more electrical traces comprises constraining at least one electrical trace based on the first slice plane and the second slice plane. 
     
     
       14. The method of  claim 6 , wherein each electrical trace is discretized into a discrete series of layers for the stored geometry, and anti-aliasing is used for each electrical trace. 
     
     
       15. The method of  claim 14 , further comprising receiving user input that sets an orientation of a normal direction of the user defined slice plane. 
     
     
       16. The method of  claim 15 , wherein the orientation of the normal direction is changed from a usual orientation along a z dimension of a three dimensional printer. 
     
     
       17. The method of  claim 16 , further comprising, wherein where two consecutive trace slices are on different slice planes, re-positioning the two consecutive trace slices to maintain electrical contact between the two consecutive trace slices. 
     
     
       18. A method comprising:
 providing, using a computing device, a design tool comprising a database of components for placement in a model; 
 receiving, using the computing device, user input comprising a selection of one or more of the components from the database and one or more corresponding locations for placement of the one or more components in the model; 
 placing electrical traces in the model, including dynamically adjusting an amount of overlap between two consecutive trace slices based on material and fabrication properties; and 
 storing a geometry of the model, wherein the stored geometry comprises structural components, electrically conductive components, and electrical traces. 
 
     
     
       19. The method of  claim 18 , further comprising storing electrical characteristics of each of the selected one or more components. 
     
     
       20. The method of  claim 18 , further comprising storing meta data relating to the physical appearance of each of the selected one or more components. 
     
     
       21. The method of  claim 18 , further comprising:
 determining an orientation of a first component among the selected one or more components; and 
 changing the orientation of a second component among the selected one or more components based on the determined orientation of the first component. 
 
     
     
       22. The method of  claim 21 , further comprising, in response to changing the orientation of the second component, automatically changing a layout of at least one of the electrical traces in the model. 
     
     
       23. The method of  claim 22 , wherein automatically changing a layout comprises optimizing for electromagnetic characteristics. 
     
     
       24. The method of  claim 18 , wherein the selected one or more of the components from the database are automatically orientated on the model based on a surface of the model.